Process of balling scrap metal



J. M. SELLERS PROCESS OF .BALLING SCRAP METAL Filed Apil s. 1922 July 31, 1923.

Patented duly 3l, i923.

para;

raras rifare-itar JOHN M. SELLEEs, oEnov-INEES GROVE, ILLINOIS, ASsIGNoEs ro SELLERS I/IAIvUEAcJ` TUEING CoMraNxoE orIIcac-dILLINos, a CORPORATION 0E ILLINOIS.

rEoCEss or 'EALLINGQ sonar ri-rE'raL.'i

Appiication ined epm s, 1922. Serin N. 54e,316;

To l' infima it may concern:

Be it known that l, Jol-IN M. SELLERS, a citizen of the 4United States, residing at Downers Grove, in the county of Du Page land State of illinois, have invented certain new andA useful improvements' in Processes of Balling Scrap Metal7 of which the following is a spec-ilication. Y

VMy invention relates to the production of a` high gradewrought iron from iron 4and steel scrap, and its object is to improve upon the method of balling or Welding the scrap into an agglomerated mass Whichlis vdisclosed in the patent to David H. Lentz, No. 1,012,871 granted December 26, 1911, for process of balling'scrap 'metal; this balling operation, s o-called, being the initial step in the process ofv manufacturing the scrap metal intobars or billets ofk wrought iron. n

in accordance with the method of the Lentz patent referred to, a charge of the scrap metal is introduced vinto asubstantially cylindrical, rotary,preheating chan ber ,whichterminates at the end opposite to that into which the meta-l is introducethin an enlarged, annular balling chamberu The pre-heating and balling chambers have the usualy refractory'lining. Heat is introduced into the balling chamber `and frointhere into the preheating chamber through a flameivay leading from a coal furnace with which the structureforming the balling and preheating chamber is aligned after the introduction of the charge into the preheating chamber.Y The charge of metal is preheated by the frame as it passes from the balling chamber and is fed into the balling' chaml berrby rotation of this structure. Thejpieces of scrap heated and partially cleansed byv agitation in the preheating chamber drop into the balling chamber Where'they are Welded into a ball by rotation of the baliing chamber, afternyvhich the rotary structure is turned away from the vfurnace and the ball removed. The hot plastic ball is then put through-a squeezer to eliminate, so far as possible,A` slag and other impurities after which the body of metal is rolled or other- Wise treated to convert the same into a billet or bar. v c

While this method has been successfully practiced on a large scale since the grant of the Lentz patent, I have discovered that, by

mak-ing certain ychanges in this method improved results of a very important character are obtained, to-Wit: a ball of softer `and purer ,metal and one invvhich theWelding of the constituents into afhom'ogeneous mass Ais more complete, "these characteristics facilitating and cheapening the subsequent operations of squeezing and rolling andv giving a materially better quality of Wrought iron; increased output for a given period of operation; reduction of fuel cost; and a very considerable saving in labor. i

Certain of these improvements relate to the apparatus employed and these improvements are described and claimed in aco the combustion in the vballing chamber itself vstantly uniform temperature produced by of a suspended fuel, preferably atomized 'f hydro-carbon oilswhich is `preferably preheated, miXed With preferably preheated air, preferably somewhat moistened, and

burned during the Welding'operatiomin immediate contact With the heated metal. The temperatureproduced in the balling and preheating chambers is increased overthat obtainable by the'old methods, the combustion of fuel ismore complete, the flame freer, y

of carbon, sulphur and other impurities likely to be carried into the metal, and the rtemperature is capable of being maintained method is used-and` practical experience with the subsequent handlingof the ball in the squeezers and rolls fully confirms the analyses.

In the accompanying. drawing l have shown, somewhat fragmentarily, an apparatus suitable for carrying out the improved process. It Will be understood, however, that the process is not limited to the use of this particular apparatus, which l do :not claim herein7 as such apparatus forms the subject matter of my co-pending application above referred to.

The drawing shows a longitudinal sectional View of the apparatus concerned, with certain parts in elevation.

,Referring to the drawing, l0 represents the ballingfurnace Which is preferably slightly inclined from horizontal and is rotated by suitable mechanism on its longitudinal axis. l1 designates the greheati chamber which is substantially cylindrical in form, and '12 the annular ballingY chamber which is of larger diameter than the preheating chamber .3 designates a structure having a. flue or fuel openingl La communieating with the opening 15 in the end of the hailing chamber. rlhe structureli is movable toward and away from the end of the ballinp; furnace and the latter is mounted on a turn table 16 so that it may be turned out of alignment with flue 11i and with the discharge flue 1'? at the other end of the fur-- nace for the purpose of removing the iin-- ished ball and "re-charging` the furnace. The structure formed with an air duct 18 surroun lingflue 14 into which yir is introduced through a jet 19 into r-hich projects the open endof a steam pipe The jet is preferably arranged so that it takes in the heated escaping from the space 2l. between the bellino; furnace and the structure 13. The ai, after being further heated in duct 18, forced by a pump 22 into an air pipe 23 provided with a nozzle Q41- which projects part ivay through the line The oil, after sing; heated, preferably, in the heater 25. is forced by auinp Q6 through a pipe 2'?, 27, provided 1.vith a nozzle which extends into the air nozzle 24. 29 is a valve for'controllingv the air and 30 a cor-.trolling valve in the oil line. vThe and oil noz' Zles are preferably formed as shown to spread the flame somewhat. f f leflred, two fuel nozzles may be employed.V The general direction of the llame is against the further side of the ballinu chamber as indicated by the arrows yThe flue may be provided with a transverse Wall 31 ranged Ydirect-ly in front of the fuel nozzle and formed with an opening ln order to ac commodate the forward and bach move*- ments of structure telescoi'iing device 38 is interposed between il sections 2T and 27a.

After the metal has been charged into the upper or left hand end of thepreheating chamber, the balling'furnace is turned so that it aligns with the flue lll and the dis charge flue 17 and is then rotates, prefer ablyA at intervals, so as nto turn over the charge of scrap and eventually bring it in a highly heated but unmelted condition into the hailing chamber 12. l mean by this that thepieces of scrap are not reduced to molten state a though they may be melted to a certain extent superlicially. In the balling; chamber it is subjected to the very high temperature produced by the combustion of atoinized oil which is mixed with air in correct proportions accurately obtained by ad- 'diustinent of valves 29, 30, this combustion taking place in the balling chamber itself, Owing' to the preheating of the charge before reaching` the calling chamber, there is no tendency to deposit carbon when the fuel spray contacts with Athe metal charge, but the highly heated charge and the highly heated refractory lining of the ballingl chamber facilitate the complete combustion of the fuel spray, and produce suc-h combustion at temperature Which produces the results sought, and permits the use of a maximum of oxygen in the fuel spray. The flame produced is a clear, oxidizing flame and it effectively burns away many of the undesir` able impurities in the met-al treat-ed.

@Wing to the complete combustion, and quick production of the maximum temperature desired, the ball is formed rapidly that there is a great reduction of furnace loss of metal, as compared with ythe bestl re` sults attained by any former practice.

l have found, by the analyses referred to, that a ball produced in this Way is softer, more homogeneous and will hold its heat longer than balls made by the Leutz process. The fact that the ball vill hold its heat longer is important as it facilitates and maires more effective the operation of squeezing, the purpose of Ywhich is to further Weld the constituents of the mass to each other and press out the slag' and other impurities.

urtherrnere, the analyses above referred to demonstrate that the iron made from a ball formed in accordance with my improvement contains less carbon, manganese, phosphorous and sulphur than iron made in ac'- cordance with the LentrA method. Vhe cornparative analyses show' generally speaking. a Wrought iron having` approximately twenty-live per cent greater purity. The 'results of these analyses are fully'conlirmcd by experience With the balls during` the later steps in the process, lit has been made quite obvious to those handling'the metal in the squeezers and rolls that the metal is softer and purer. lt is Worked .more easily. iiame to which the metal is subjected is nc-f onlv a -eurer flame than is obtainable Vby the -tain the necessary temperatureconditions forY balling. Between these times the quality vand temperature of the flameare constantly changing. As a result the cold metal charged into the preheating'chamber was Y subjected at first to a relatively low temperaheat the air of the fuel charge to a temperture lflame which was likely to be quite smoky.

Furthermore, by my improved processI increase output over the Leutz process because I am enabled toproduce each ball in a much shorter period of treatment and thereby make a considerable saving in the cost of fuel per ton of iron produced.

Over a considerable period of constant operation the production per hour of operation with the same balling machine is per cent greater with my new process than with .the described Lentz process, but owing to the uninterrupted efficient operations for reasons previously noted, the output per day is increased over per cent.

In the matter of labor, I operate my process with only four of the seven menrequireg per machine with the Lentz process.

In carrying outthe method I prefer to use air at a pressure of .approximately three ounces per square inch and to preature of approximately Fahrenheit. The oil is injected at a'pressure of about 130 pounds per square inch and is preheated toY a temperature of about 1800 Fahrenheit. It will be realized, however, that these temperatures .and pressures will be varied atc-f cording `to the particular apparatus employed and the character of the materia-l treated, quality of fuel oilused, temperature desired, and other conditions of like character. Y Y

The hydrocarbon oil or other carbon bearing fuel How and air flow, to form the fuel spray, should of course be so adjusted as to y produce the best results as to complete combustion and high resulting temperature.

While a slag yor cinder bath is desirable to get best results in forming the ball, excessive or old cinder may be tapped oft from time to time by driving a tap hole in the'periphery of the balling chamber. Such hole can be plugged in any familiar manner such as with a short bar of iron, which can 4Velements.

be driven'in later when desired to'again tap the chamber.

In operation it will be observedifthat the v fuel insuspension is inthe form of forced `7.0

spray of carbon and oxygen bearing elements, such as fuel-oil and air, which may be controllably and'properly proportioned to, insure complete combustion at 'a very4 I high temperature. n Y

-During the preliminary heating. of .the chamber the fuel element proportions maybe varied as may be necessary to obtainperfect combustion under these preliminary con` ditions. Y r

The combustion of fuel quickly raises the the refracchamber to more slowly to likewise bring tory lining of the preheating a high temperature. Y

v'Ihen the preheating chamber ischarged with a charge of scraplin relatively small pieces, wh'ich by the rotationof the apparatus becomes .spread in a thin layer over the yheated lining of the preheating chamber, the pieces of scrap being ,turnedv` veyed thereby to the balling chamber.

The speed of rotation preferably so controlled that theparticles of lscrap drop into the ballingchamber where is the vzone of the most intense heat, when they have been heated to such anV extent that V 'they will readily weld into a' ball in the balling chamber. i

As the preheated pieces of scrap ldrop into the balling chamber, the lfuel spray pinges on the-scrap.A

Owingto the highly heated lconditi-fon of the scrap, there is no tendency-toV precipiVY so'v refractory lining in the hailing chamberl to a white heat' and thel escaping heat serves" over by further rotation and gradually contate or separate any of the suspendedfuel .On the ffcontrar'y, the heated scraplfacilitates the forma-tion and complete combustion of lhighly combustible gases from the fuel spray which burn Vwithout visible flame or'smoke.v w

Thereby I attain: a

vSubstantially' perfect combustion and resulting economy of fuel. c A- maximum temperature wherebyv the charge is heated and the ball Vformed much more rapidly, thereby increasingl the output per machine over 100 per cent. "x

A quickly and more complete oxidation of carbon and other impurities in the charge, thereby producing not only apurer iron, but a softer and hotter ball which can bemore quickly and economically worked.

A complete combustion whereby precipitation on the charge Aof unconsumed fuel elements or products of combustion is avoided. Y

A uniformity of temperature, whereby 'a more regular vcycle of operation may be.

`lll) Vby rolling, While subjected to a high temperature produced by the combustion or a fuel in suspension in immediate cont-act With suchV metal in the space in which the metal is balled.

2. Method or' manufacturing Wrought viron from metal scrap which comprises preheating the scrap Without reducing it A to' a. molten state, and then collecting a charge of the preheated metal and balling it by rolling, While subjected to a high temperature produced by the combustion ol' a. Afinely divided preheated fuel introduced with a preheated oXygen bearing j. element burned in suspension in immediate contact Vwith the metal charge in the space in which the metal is balled. Y

3. Method of manufacturing Wrought iron from metal scrap which comprises preheating the `scrapyithout reducing to a molten state7 Vand then collecting charge of the preheated metal and 1yoalling it by rolling, While subjected'to a. high temperature produced by the combustion of a fluid fuel introduced intoA and burned in suspension in the space in which the metal is balled in immediate contact `with such metal.

a. Method of manufacturing `wrought iron from scrap Which comprises subjecting the scrap While spread out over an extended surface to a flame to preheat it Without reducing it to a. molten state, then collecting va charge of the metal and balling it by rolling While subjected to a higher temperature than the preheating temperature nroduced by the combustion of a fluid :tuer introduced into and burned in suspension in Athe space in Which the metal is balled 1n immediate Contact with such instal.

5. Method of manufacturing wrought iron from scrap metal which comprises preheating the scrap Without reducing it to e molten state7 and then collecting a charge of the preheated metal and balling it by rolling While subjected to a'high temperature produced by the combustion of a hyand drocarbon oil introduced in an atomized condition into and burned in suspension in the space in which the metal is balled.

6. llflethod of manufacturing Wrought iron from scrap metal which comprises suhjecting the scrap While spread out over an extended suriace to a llame to preheat it Without reducing it to a molten state7 then collecting a charge ot the metal and balling it by rolling While subjected to a higher temperature than the preheating temperature produced by the. combustion oi' a hydrocarbon oil introduced in atoniized condition into and burned in suspension in the space in which the metal is balled.

7. lylethod of' manufacturing Wrought iron from `scrap which comprises preheating the scrap Without reducing it to a molten condition and then collecting a el 'e of the 1preheated metal and balling e1 lture produced by the combustion of a preheated hydrocarbon oil introduced in atoniized condition with preheated air and moisture into and burned in suspension in the space in which the metal is balled.

S. l/lethod of balling scrap metal which tonsists in causing the metal to pass While out and subjected to 'agitation IVirc-ugh a preheating zone into a balling "nace and there collecting and rolling the ted metal into a ball, and producing Welling heat inthe balling space7 and a Oree of heat in the preheating zone, er heats without melting the mel eheatingzone, by the combusti lo balling space 01' a hydrocarbon oil the conduction of the Vdames 'from the lingspace through the preheating Zone. 9. llethod of vballing scrap metal which consists in causing the metal `jto pass While spread out` and subjected to agitation through a preheating zone into a balling space and there collecting and rolling the preheated metal into a ball, and producing a Weleing heat in the helling space, and lower degree of heat in the preheating zone which latter heats Without melting the metal in said preheating zone, by the Ycombustion the balling space of a suspended finely vided fuel and the conduction of the llames from the hailing space through the preheating zone.

JOHN M. SELLERS,

t by rolling `while subjected to a high tem- 

